Metal magnetic powder core production process capable of utilizing waste

Abstract

The invention provides a metal magnetic powder core production process capable of utilizing waste materials, belongs to the technical field of metal magnetic powder cores, and solves the technical problem that metal waste materials cannot be directly utilized to produce metal magnetic powder cores in an existing metal magnetic powder core production process. The method comprises the following steps: smelting an alloy; pulverizing the waste materials; adding materials and preparing powder; insulating coating; and pressing and annealing. According to the metal magnetic powder core machining device, mechanical waste materials are smelted and crushed, the waste materials can be directly utilized for metal magnetic powder core machining, compared with existing chemical cleaning, large-scale popularization and utilization are facilitated, the leakage hole is formed in the bottom of the smelting furnace, and under the action of the rotating plate rotationally arranged at the bottom of the leakage hole, the metal magnetic powder core machining efficiency is improved. The smelting furnace can directly smelt the magnetic metal waste through the cooling box, granulation is conducted through the rotating plate, the recycling effect of the waste is ensured, and the screen is arranged in the cooling box to collect metal particles.

Description

Technical Field

[0001] The invention belongs to the technical field of metal magnetic powder cores and relates to a metal magnetic powder core production process, in particular to a metal magnetic powder core production process that can utilize waste materials. Background Art

[0002] Metal magnetic powder core material is composed of metal soft magnetic powder, organic or inorganic insulating additives and binder. It is a soft magnetic composite material made of metal soft magnetic powder as raw material through insulation coating, pressing molding and heat treatment. It has the characteristics of small high-frequency eddy current loss, good temperature stability, good frequency characteristics, constant magnetic conductivity, high saturation magnetic induction intensity, etc. It is used in functional components such as line filters, pulse transformers, power inductors, etc. It has unparalleled advantages over other materials and has developed rapidly. It has grown into a very important member of the soft magnetic material family and is playing an increasingly important role in related fields such as energy conversion and information processing.

[0003] After searching, for example, Chinese patent documents disclose a method for recovering and reusing soft magnetic metal powder from waste magnetic powder cores [Application number: CN201711032483.3; Publication number: CN107876782A]. This method for recovering and reusing soft magnetic metal powder relates to the technical field of metal powder material preparation. The document discloses that the organic binder and coating material on the surface of soft magnetic metal powder particles can be removed by using the principle of like dissolves like and the solvent swelling method, and waste magnetic powder cores can be recovered. The soft magnetic powder can be completely recovered without destroying the soft magnetic powder itself, and good magnetic properties are retained.

[0004] Although the method for recovering and reusing soft magnetic metal powder disclosed in this patent achieves the performance of commercial metal magnetic powder cores by preparing the recycled metal magnetic powder cores through the recycling and regeneration method, the method for recovering and reusing soft magnetic metal powders involves rinsing and treating the soft magnetic metal powders with organic solvents. During the soft magnetic cleaning of different materials, the magnetic suspension may penetrate the magnetic powders, affecting the working performance of the magnetic powders. In addition, the soft magnetic metal powders need to be collected and processed, which has poor practicality. In addition, the chemical solvents in the organic solvents are harmful to the human body and affect human health. Summary of the invention

[0005] The purpose of the present invention is to address the above problems in the existing technology and to propose a metal magnetic powder core production process that can utilize waste materials. The technical problem to be solved by the invention is: how to realize the production of metal magnetic powder cores directly utilizing metal waste materials.

[0006] The purpose of the present invention can be achieved by the following technical solutions:

[0007] A process for producing a metal magnetic powder core that can utilize waste materials comprises the following steps:

[0008] S1. Alloy smelting: silicon steel scrap or magnetic metal scrap is smelted at high temperature in a smelting mixing furnace, and efficient metal granulation is performed after smelting to facilitate subsequent powder processing;

[0009] S2. Waste pulverization: The waste is granulated and effectively crushed, and the metal components are tested after being evenly mixed in a mixing box, and the required metal components are analyzed;

[0010] S3, adding materials and making powder: adding the required metal components inside the mixing box, and performing synchronous and efficient mixing through the mixing box to ensure the powder making effect;

[0011] S4, insulation coating: suspending metal powder particles in an organic solution of phosphoric acid and epoxy resin to form a solid fluid for insulation coating;

[0012] S5. Pressing and annealing treatment: Use warm pressing to press the insulated coated metal magnetic powder into a green billet, and use annealing heat treatment to eliminate internal stress to ensure the magnetic properties of the metal magnetic powder core.

[0013] The impurities of the metal component powder in steps S3 and S2 are less than 500 ppm, and the particle size is 3-5 μm.

[0014] The warm pressing method in step S5 is to heat the powder and the mold to 120°C-135°C, and perform warm pressing at a pressure of 1100-1800 MPa and a temperature of 100°C-120°C.

[0015] The annealing heat treatment method in step S5 is to gradually increase the temperature from room temperature to an annealing temperature of 480° C.-680° C., and the annealing time is 0.5 h-2 h.

[0016] The equipment used in steps S1-S3 is a smelting and powder making device;

[0017] The smelting and powder making device comprises a smelting furnace, a mixing box and a fixed frame, and a cooling box fixedly mounted on the surface of the fixed frame, the top of the cooling box is fixedly connected to the smelting furnace, and a leakage hole is opened at the bottom of the smelting furnace, and a smelting and granulating component is connected to the bottom of the leakage hole, a material guide trough is fixedly connected to one side of the cooling box, and a crushing component is fixedly connected to the bottom of the material guide trough, and the crushing component and the smelting and granulating component are transmission-connected;

[0018] The smelting and granulating assembly includes a rotating plate, and the rotating plate is rotatably connected to the top of the cooling box, the outer wall of the rotating plate is fixedly connected to a bevel gear ring, and the surface of the bevel gear ring is meshedly connected to a bevel gear, the outer wall of the bevel gear is fixedly connected to a rotating rod, and the rotating rod is rotatably connected to the top of the cooling box, the rotating rod is driven by a driving unit, and the rotating rod is transmission-connected to a pulverizing assembly;

[0019] The crushing assembly includes a crushing box, and the crushing box is fixedly installed on the outer wall of the cooling box, the top of the crushing box is fixedly connected to a top plate, and the top of the top plate is fixedly connected to the bottom end of the material guide trough, the inside of the crushing box is rotatably connected to two crushing rollers, and the outer walls of the crushing rollers are meshed and connected with material plates, and the material plates are fixedly connected to the inner wall of the crushing box;

[0020] The bottom end of the crushing box is fixedly connected with a feeding pipe, and the bottom end of the feeding pipe is fixedly connected with a mixing box, a circulation pipe is spirally wound on the outer wall of the mixing box, and a detection rod is rotatably connected inside the mixing box, and the detection rod is transmission-connected with the crushing assembly, and one end of the mixing box is rotatably connected with a feeding assembly;

[0021] One end of the circulation pipe is fixedly connected to a connecting pipe, and the other end of the circulation pipe is connected to the inner lower part of the cooling box through a circulation water pump;

[0022] A high-pressure nozzle is fixedly installed at the other end of the connecting pipe, and the high-pressure nozzle is located in the upper inner part of the cooling box. An obliquely installed screen is arranged below the high-pressure nozzle, and the screen is fixedly installed on the inner wall of the cooling box.

[0023] In the present invention, silicon steel scrap or magnetic metal scrap is introduced into a smelting furnace for high-temperature smelting, a leak hole is arranged at the bottom of the smelting furnace, and the smelted metal solution moves downward through the leak hole. Under the action of a rotating plate arranged at the bottom of the leak hole, a bevel gear ring is fixedly connected to the outer wall of the rotating plate, and under the meshing action of the bevel gear and the bevel gear ring, when the bevel gear is rotated by a driving motor, the bevel gear ring drives the rotating plate to rotate at the bottom of the leak hole, so that the rotating plate pelletizes the metal solution flowing inside the leak hole, and a cooling box is arranged at the bottom of the rotating plate, and a screen is fixedly connected inside the cooling box. Under the action of the high-pressure nozzle above the screen, the granulated metal particles are collected by the screen, and the high-pressure nozzle is connected to the circulating water pump through the connecting pipe, so that the cooling water at the bottom of the cooling box can be circulated, and the metal particles on the surface of the screen are cooled by the high-pressure nozzle, so that the forming effect of the metal particles is ensured, and under the action of the oblique setting of the screen, the metal particles on the surface of the screen pass through the guide groove into the crushing box, and the first synchronous belt is connected to the connecting rod through the transmission connection, so that when the driving motor rotates, the crushing roller rotates synchronously inside the crushing box, so that The two crushing rollers can efficiently crush the metal into powder inside the crushing box, and by connecting the feeding roller at the bottom of the crushing box, the crushed metal magnetic powder enters the mixing box. Under the action of the circulation pipe connected to the outer wall of the mixing box, the circulating water with temperature is wrapped around the outer wall of the mixing box for cooling, which extends the cooling path of the circulation pipe and ensures the cooling effect. The circulation pipe with a certain temperature is heated on the outer wall of the mixing box to avoid the metal magnetic powder from hanging on the wall and sticking inside the mixing box. In addition, by arranging a detection rod inside the mixing box, the detection rod can pass through the mixing box. It rotates inside the mixing box through the transmission of the second synchronous belt, which is convenient for component detection of the metal material inside and control of the electric motor. When the electric motor is energized, the gear plate rotates, and the gear plate is meshed with the outer gear ring. Under the action of the outer gear ring fixedly installed on the outer wall of the mixing box, the feeding assembly can feed into the interior of the mixing box through the material through the material hole, thereby ensuring the mixing effect of the magnetic powder inside the mixing box, and by arranging multiple material distribution chambers inside the rotating barrel, different metal magnetic powders can be fed into the interior of the mixing box conveniently, thereby ensuring the working efficiency of the mixing box.

[0024] The driving unit is a driving motor, and the output end of the driving motor is fixedly connected to a rotating rod, and the driving motor is fixedly installed on one side of the cooling box;

[0025] The outer wall of the rotating plate is fixedly connected with a first sliding block, and the first sliding block is slidably connected to the inside of the cooling box.

[0026] By adopting the above structure and setting the driving motor, the rotating rod can be stably driven, which is convenient for driving the bevel gear to rotate stably. Moreover, by fixing the first slider on the outer wall of the rotating plate, the rotating plate can rotate stably on the top of the cooling box, thereby ensuring the rotation path of the rotating plate.

[0027] The feeding assembly includes a rotating barrel, and the rotating barrel is rotatably connected to one end of a mixing box. A plurality of material distribution cavities are annularly arranged inside the rotating barrel, and a feeding port is opened on one side of each material distribution cavity. The feeding port is in contact with the outer wall of the mixing box, and a material passage hole is opened on the surface of the mixing box.

[0028] With the above structure, under the action of the feeding component, the feeding component can feed into the interior of the mixing box through the feeding hole, thereby ensuring the mixing effect of the magnetic powder inside the mixing box, and by arranging multiple material distribution chambers inside the rotating barrel, it is convenient to feed different metal magnetic powders into the interior of the mixing box, thereby ensuring the working efficiency of the mixing box.

[0029] The outer wall of the rotating barrel is fixedly connected to an electric motor, and the output end of the electric motor is fixedly connected to a gear plate, the bottom end of the gear plate is meshedly connected to an outer gear ring, and the outer gear ring is fixedly connected to the outer wall of the mixing box;

[0030] The inner wall of the rotating barrel is fixedly connected with a second sliding block, and the second sliding block is slidably connected to the outer wall of the mixing box.

[0031] By adopting the above structure, by rotating the connected gear plate above the rotating barrel, under the meshing action of the gear ring and the outer gear ring, the gear plate can realize circular rotation when the outer wall of the outer gear ring rotates, thereby ensuring the rotation effect of the rotating barrel, and by fixing the second slider on the inner wall of the rotating barrel, the rotation path of the rotating barrel is accurate, thereby ensuring the accuracy of feeding the rotating barrel.

[0032] Both ends of the two crushing rollers are fixedly connected with gear plates, and the gear plates are located on the outer wall of the crushing box, one end of one of the crushing rollers is fixedly connected with a connecting rod, the outer wall of the connecting rod is fixedly connected with a first synchronous wheel, and the outer wall of the first synchronous wheel is meshed with a first synchronous belt, the top inner wall of the first synchronous belt is meshed with a second synchronous wheel, and the second synchronous wheel is fixedly installed on the outer wall of the rotating rod.

[0033] By adopting the above structure, gear plates are fixedly connected at both ends of the two crushing rollers. Under the action of the mutual meshing of the two gear plates, the two crushing rollers can synchronously and efficiently crush the metal particles. Under the action of the material plates arranged on both sides of the two crushing rollers, the material plates are stably guided into the interior of the crushing box, ensuring that the metal particles are efficiently crushed by the crushing rollers.

[0034] The outer wall of the detection rod is fixedly connected with a third synchronous wheel, and the third synchronous wheel is located at the outer end of the mixing box, the outer wall of the third synchronous wheel is meshedly connected with a second synchronous belt, and the top inner wall of the second synchronous belt is meshed with a fourth synchronous wheel, and the fourth synchronous wheel is fixedly installed on the outer wall of the connecting rod.

[0035] With the above structure, under the action of the second synchronization, the detection rod and the connecting rod are rotated synchronously, ensuring the production synchronization of metal magnetic powder crushing and mixing, and the structure is simple and the driving cost is low.

[0036] Compared with the prior art, the metal magnetic powder core production process of the present invention that can utilize waste materials has the following advantages:

[0037] 1. In the present invention, by mechanically smelting and crushing the waste, the waste can be directly used for metal magnetic powder core processing. Compared with the existing chemical cleaning, it is convenient for large-scale promotion and utilization. Moreover, by arranging a leak hole at the bottom of the smelting furnace and rotating a rotating plate at the bottom of the leak hole, the smelting furnace can directly melt the magnetic metal waste and granulate it through the rotating plate, thereby ensuring the recycling effect of the waste. Moreover, by arranging a screen inside the cooling box to collect the metal particles, it is convenient for the subsequent crushing and powdering of the metal particles. Compared with the existing method of cleaning and utilizing the magnetic powder, it is convenient for large-scale processing of the magnetic metal waste, and the transmission efficiency is high and the processing synchronization is good.

[0038] 2. In the present invention, by arranging a high-pressure nozzle above the cooling box, the high-pressure nozzle can quickly and effectively cool down the metal particles on the surface of the screen, ensuring the forming efficiency of the metal particles, and by connecting the high-pressure nozzle with the connecting pipe, under the connection of the connecting pipe with the circulating water pump through the circulating pipe, the warm cooling water can be circulated and reused through the circulating pipe, and by sleeved the circulating pipe on the outer wall of the mixing box, the cooling path of the cooling water in the circulating pipe is extended, ensuring the cooling effect, and the circulating pipe with a certain temperature is heated on the outer wall of the mixing box, avoiding the metal magnetic powder from hanging on the wall and sticking inside the mixing box, which is beneficial to improving the mixing effect of the mixing box, and the structure is compact and practical.

[0039] 3. In the present invention, a crushing box is arranged on one side of the cooling box, so that metal particles can be efficiently pulverized in the crushing box, thereby ensuring the processing effect of metal magnetic powder. Moreover, by connecting the crushing assembly with the smelting granulation assembly through transmission, it is convenient to drive the crushing roller to rotate synchronously by the driving motor, thereby ensuring the synchronization of metal granulation and crushing. Moreover, by connecting the second synchronous belt through the transmission on the outer wall of the connecting rod, the crushing roller and the detection rod can rotate synchronously, thereby realizing the synchronous transmission of the detection rod inside the mixing box, thereby facilitating the synchronous detection of the magnetic powder inside the mixing box, effectively saving the driving resources of the device, and ensuring the synchronization of the production of metal magnetic powder cores.

[0040] 4. In the present invention, under the action of the feeding assembly arranged on one side of the mixing box, the gear ring is meshed with the outer gear ring, so that the gear plate can realize circular rotation when the outer wall of the outer gear ring rotates and rotates, ensuring the rotation effect of the rotating barrel. Then, the feeding assembly can feed into the interior of the mixing box through the material through hole, which is beneficial to realize the mixing effect of the magnetic powder inside the mixing box, and by arranging a plurality of material distribution chambers inside the rotating barrel, it is convenient to feed different metal magnetic powders into the interior of the mixing box, ensuring the working efficiency of the mixing box, and. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 It is a preparation flow chart of the present invention.

[0042] Figure 2 It is a schematic diagram of the structure of the smelting and powder making device in the present invention.

[0043] Figure 3 The present invention Figure 2 A is an enlarged structural diagram of FIG.

[0044] Figure 4 It is a schematic diagram of the structure of the smelting and granulating component and the crushing component in the present invention.

[0045] Figure 5 It is a schematic diagram of the cross-sectional structure of the smelting and granulating component and the crushing component in the present invention.

[0046] Figure 6 It is a schematic diagram of the cross-sectional structure of the feeding assembly and the mixing box in the present invention.

[0047] Figure 7 It is a schematic diagram of the cross-sectional three-dimensional structure of the feeding assembly and the mixing box in the present invention.

[0048] Figure 8 It is a structural schematic diagram of the feeding component in the present invention.

[0049] Fig. 9 It is a schematic diagram of the cross-sectional structure of the feeding assembly in the present invention;

[0050] Fig.10It is a schematic diagram of comparative data of experimental examples in the present invention.

[0051] In the figure, 1, fixed frame; 2, cooling box; 3, smelting furnace; 4, leakage hole; 5, rotating plate; 6, first slider; 7, bevel gear ring; 8, bevel gear; 9, rotating rod; 10, driving motor; 11, screen; 12, high-pressure nozzle; 13, material guide trough; 14, top plate; 15, crushing box; 16, material plate; 17, crushing roller; 18, gear plate; 19, connecting rod; 20, first synchronous wheel; 21, first synchronous belt; 22, second synchronous wheel; 23, material pipe; 24, mixing box; 25, circulation pipe; 26, connecting pipe; 27, detection rod; 28, third synchronous wheel; 29, second synchronous belt; 30, fourth synchronous wheel; 31, rotating barrel; 32, material distribution chamber; 33, feeding port; 34, second slider; 35, electric motor; 36, gear plate; 37, outer gear ring; 38, material hole. DETAILED DESCRIPTION

[0052] The following are specific embodiments of the present invention and the accompanying drawings to further describe the technical solution of the present invention, but the present invention is not limited to these embodiments.

[0053] Example 1

[0054] The present invention provides a process for producing a metal magnetic powder core that can utilize waste materials, comprising the following steps:

[0055] S1. Alloy smelting: silicon steel scrap or magnetic metal scrap is smelted at high temperature in a smelting mixing furnace, and efficient metal granulation is performed after smelting to facilitate subsequent powder processing;

[0056] S2. Waste pulverization: The waste is granulated and effectively crushed, and the metal components are tested after being evenly mixed in a mixing box, and the required metal components are analyzed;

[0057] S3, adding materials and making powder: adding the required metal components inside the mixing box, and performing synchronous and efficient mixing through the mixing box to ensure the powder making effect;

[0058] S4, insulation coating: suspending metal powder particles in an organic solution of phosphoric acid and epoxy resin to form a solid fluid for insulation coating;

[0059] S5. Pressing and annealing treatment: Use warm pressing to press the insulated coated metal magnetic powder into a green billet, and use annealing heat treatment to eliminate internal stress to ensure the magnetic properties of the metal magnetic powder core.

[0060] The impurities of the metal component powder in steps S3 and S2 were 500 ppm and the particle size was 3 μm.

[0061] The warm pressing method in step S5 is to heat the powder and the mold to 120°C and perform warm pressing at a pressure of 1100°C and a temperature of 100°C.

[0062] The annealing heat treatment method in step S5 is to gradually increase the temperature from room temperature to 480° C., and the annealing time is 2 hours.

[0063] The smelting mixing furnace and mixing box in steps S1, S2 and S3 are smelting powder making devices;

[0064] The smelting and powder making device includes a fixed frame 1, a cooling box 2 fixedly mounted on the surface of the fixed frame 1, a smelting furnace 3, a leak hole 4, a rotating plate 5, a first slider 6, a bevel gear ring 7, a bevel gear 8, a rotating rod 9, a driving motor 10, a screen 11, a high-pressure nozzle 12, a material guide trough 13, a top plate 14, a crushing box 15, a material plate 16, a crushing roller 17, a gear plate 18, a connecting rod 19, a first synchronous wheel 20, a first synchronous belt 21, a second synchronous wheel 22, a material pipe 23, a mixing box 24, a circulation pipe 25, a connecting pipe 26, a detection rod 27, a third synchronous wheel 28, and a second synchronous belt 2 9. The fourth synchronous wheel 30, the rotating barrel 31, the material distribution chamber 32, the feeding port 33, the second slider 34, the electric motor 35, the gear plate 36, the outer gear ring 37 and the material through hole 38. The top of the cooling box 2 is fixedly connected with the smelting furnace 3, and the bottom of the smelting furnace 3 is provided with a leakage hole 4, so that the molten metal after smelting can leak down through the leakage hole 4, and the bottom of the leakage hole 4 is connected with the smelting and granulating component. At the same time, a material guide trough 13 is fixedly connected to one side of the cooling box 2, and the bottom of the material guide trough 13 is fixedly connected with a crushing component, and the crushing component and the smelting and granulating component are transmission-connected;

[0065] Furthermore, the smelting and granulating assembly includes a rotating plate 5, and the rotating plate 5 is rotatably connected to the top of the cooling box 2. In order to ensure the rotation effect of the rotating plate 5, a first slider 6 is fixedly connected to the outer wall of the rotating plate 5, and the first slider 6 is slidably connected to the inside of the cooling box 2, which is convenient for limiting the rotation path of the rotating plate 5. At the same time, a bevel gear ring 7 is fixedly connected to the outer wall of the rotating plate 5, and a bevel gear 8 is meshedly connected to the surface of the bevel gear ring 7. Through such an arrangement, the bevel gear 8 can drive the bevel gear ring 7 to rotate by rotation, which is convenient for driving the rotating plate 5. In order to realize the rotation effect of the bevel gear 8, a rotating rod 9 is fixedly connected to the outer wall of the bevel gear 8, and the rotating rod 9 is rotatably connected to the top of the cooling box 2, and the rotating rod 9 is driven by a driving unit. Specifically, the driving unit is a driving motor 10, and the output end of the driving motor 10 is fixedly connected to the rotating rod 9, and the driving motor 10 is fixedly installed on one side of the cooling box 2. Through such an arrangement, the driving motor 10 can stably drive the rotating rod 9 to rotate, thereby realizing the transmission effect of the bevel gear 8 driving the bevel gear ring 7, and the rotating rod 9 is also transmission-connected with a crushing assembly;

[0066] The crushing assembly includes a crushing box 15, and the crushing box 15 is fixedly installed on the outer wall of the cooling box 2 to ensure the working effect of the crushing box 15, and a top plate 14 is fixedly connected to the top of the crushing box 15, and the top of the top plate 14 is fixedly connected to the bottom end of the guide trough 13. Through such a setting, the metal particles inside the guide trough 13 can directly enter the inside of the crushing box 15, and under the action of the top plate 14, the sealing of the guide trough 13 and the crushing box 15 is ensured, and the safety of material movement is achieved. Considering the crushing effect inside the crushing box 15, two crushing rollers 17 are rotatably connected inside the crushing box 15, and in order to achieve the crushing effect of the crushing box 15 on the metal magnetic powder, a material plate 16 is meshed and connected to the outer wall of the crushing roller 17, and the material plate 16 is fixedly connected to the inner wall of the crushing box 15. Through such a setting, the metal magnetic powder is fully squeezed and crushed inside the crushing box 15, which is conducive to ensuring the particle size of the metal magnetic powder;

[0067] After the crushing box 15 crushes the metal magnetic powder, in order to realize the discharge of the magnetic powder, a feeding pipe 23 is fixedly connected to the bottom end of the crushing box 15, and the bottom end of the feeding pipe 23 is fixedly connected to the mixing box 24. At the same time, a circulation pipe 25 is spirally wound on the outer wall of the mixing box 24, and a connecting pipe 26 is fixedly connected to one end of the circulation pipe 25, and the other end of the circulation pipe 25 is connected to the inner bottom of the cooling box 2 through a circulation water pump. Through such an arrangement, the cooling water in the circulation pipe 25 is wound and rotated on the outer wall of the mixing box 24, and a connecting pipe 26 is fixedly installed on the other end of the connecting pipe 26. There is a high-pressure nozzle 12, and the high-pressure nozzle 12 is located at the upper inner part of the cooling box 2. An obliquely installed screen 11 is provided below the high-pressure nozzle 12, and the screen 11 is fixedly installed on the inner wall of the cooling box 2, so that the screen 11 can isolate the metal particles. Under the action of the high-pressure nozzle 12, the cooled circulating water can pass through the high-pressure nozzle 12 to cool the metal particles inside the cooling box 2, and under the action of the circulating water pump, the circulating water with temperature is wrapped around the outer wall of the mixing box 24 for cooling, extending the cooling path of the circulating pipe 25, ensuring the cooling effect, and The circulation pipe 25 with a certain temperature is heated on the outer wall of the mixing box 24, so that the metal magnetic powder is prevented from hanging on the wall and sticking inside the mixing box 24, which is beneficial to improving the mixing effect of the mixing box 24. At the same time, a detection rod 27 is rotatably connected inside the mixing box 24. The detection rod 27 is a mass spectrometer detection rod 27, and the model of the detection rod 27 is QL-SG02-065-1A, which is convenient for the detection rod 27 to detect the distribution of the metal components inside the mixing box 24. In addition, considering the rotation of the detection rod 27, the detection rod 27 is connected to the crushing assembly in a transmission manner. Specifically, A third synchronous wheel 28 is fixedly connected to the outer wall of the detection rod 27, and the third synchronous wheel 28 is located at the outer end of the mixing box 24. The outer wall of the third synchronous wheel 28 is meshed with a second synchronous belt 29, and the top inner wall of the second synchronous belt 29 is meshed with a fourth synchronous wheel 30, and the fourth synchronous wheel 30 is fixedly installed on the outer wall of the connecting rod 19. Through such an arrangement, the detection rod 27 and the connecting rod 19 rotate synchronously, ensuring the production synchronization of the metal magnetic powder, and the structure is simple and the driving cost is low. At the same time, a feeding component is also rotatably connected to one end of the mixing box 24.

[0068] The feeding assembly includes a rotating barrel 31, and the rotating barrel 31 is rotatably connected to one end of the mixing box 24, the inner wall of the rotating barrel 31 is fixedly connected to a second slider 34, and the second slider 34 is slidably connected to the outer wall of the mixing box 24, the inner ring of the rotating barrel 31 is provided with a plurality of distribution chambers 32, and a feeding port 33 is provided on one side of each distribution chamber 32, the feeding port 33 is fitted with the outer wall of the mixing box 24, and a through hole 38 is provided on the surface of the mixing box 24, the outer wall of the rotating barrel 31 is fixedly connected to an electric motor 35, and the output end of the electric motor 35 is fixedly connected to a gear plate 36, the bottom end of the gear plate 36 is meshingly connected to an outer gear ring 37, and the outer gear ring 37 is fixedly connected to the outer wall of the mixing box 24.

[0069] Both ends of the two crushing rollers 17 are fixedly connected with gear plates 18, and the gear plates 18 are located on the outer wall of the crushing box 15. By fixing the gear plates 18 at both ends of the two crushing rollers 17, the two crushing rollers 17 can synchronously and efficiently crush the metal particles under the action of the mutual meshing of the two gear plates 18. At the same time, considering the transmission of the crushing rollers 17, one end of one of the crushing rollers 17 is fixedly connected with a connecting rod 19, the outer wall of the connecting rod 19 is fixedly connected with a first synchronous wheel 20, and the outer wall of the first synchronous wheel 20 is meshingly sleeved with a first synchronous belt 21, the top inner wall of the first synchronous belt 21 is meshingly connected with a second synchronous wheel 22, and the second synchronous wheel 22 is fixedly installed on the outer wall of the rotating rod 9.

[0070] Working principle: silicon steel scrap or magnetic metal scrap is put into the smelting furnace 3 for high-temperature smelting. By setting a leak hole 4 at the bottom of the smelting furnace 3, the smelted metal solution moves downward through the leak hole 4. Under the action of the rotating plate 5 set at the bottom of the leak hole 4, the outer wall of the rotating plate 5 is fixedly connected to the bevel gear ring 7. Under the meshing action of the bevel gear 8 and the bevel gear ring 7, when the bevel gear 8 is rotated by the driving motor 10, the bevel gear ring 7 drives the rotating plate 5 to rotate at the bottom of the leak hole 4, so that the rotating plate 5 pelletizes the metal solution flowing inside the leak hole 4. By setting a cooling box 2 at the bottom of the rotating plate 5, and fixing the screen 11 inside the cooling box 2, the pelletized metal particles are screened. The metal particles on the surface of the screen 11 are collected by the screen 11, and a high-pressure nozzle 12 is arranged above the screen 11. Under the action of the circulating water pump connected to the high-pressure nozzle 12 through the connecting pipe 26, the cooling water at the bottom of the cooling box 2 can be circulated, and the metal particles on the surface of the screen 11 are cooled by the high-pressure nozzle 12, thereby ensuring the forming effect of the metal particles. Moreover, under the action of the oblique setting of the screen 11, the metal particles on the surface of the screen 11 enter the crushing box 15 through the guide groove 13, and the first synchronous belt 21 is connected to the connecting rod 19 through the transmission connection. When the driving motor 10 rotates, the crushing roller 17 rotates synchronously inside the crushing box 15, so that the two crushing rollers 17 are in the crushing box 15. The metal can be efficiently crushed and powdered inside, and by connecting a feed roller at the bottom of the crushing box 15, the crushed metal magnetic powder enters the mixing box 24. Under the action of the circulation pipe 25 connected to the outer wall of the mixing box 24, the circulating water with temperature is wrapped around the outer wall of the mixing box 24 to cool it down, extending the cooling path of the circulation pipe 25, ensuring the cooling effect, and making the circulation pipe 25 with a certain temperature heat the outer wall of the mixing box 24, avoiding the metal magnetic powder from hanging on the wall and sticking inside the mixing box 24. In addition, by arranging a detection rod 27 inside the mixing box 24, the detection rod 27 can be driven by the second synchronous belt 29 inside the mixing box 24. Rotation is convenient for detecting the composition of the metal material inside and for controlling the electric motor 35. When the electric motor 35 is powered on, the gear plate 36 is rotated, and the gear plate 36 is meshed with the outer gear ring 37. Under the action of the outer gear ring 37 fixedly installed on the outer wall of the mixing box 24, the feeding assembly can feed into the mixing box 24 through the material through hole 38, thereby ensuring the mixing effect of the magnetic powder inside the mixing box 24. In addition, by arranging multiple material distribution chambers 32 inside the rotating barrel 31, different metal magnetic powders can be easily fed into the mixing box 24, thereby ensuring the working efficiency of the mixing box 24, thereby completing the production process of metal magnetic powder cores using waste materials.

[0071] Example 2

[0072] The difference between this embodiment and embodiment 1 is that the impurity of the metal component powder in steps S3 and S2 is 400 ppm and the particle size is 4 μm.

[0073] The warm pressing method in step S5 is to heat the powder and the mold to 130°C and perform warm pressing at a pressure of 1400 MPa and a temperature of 110°C.

[0074] The annealing heat treatment method in step S5 is to gradually increase the temperature from room temperature to 550° C., and the annealing time is 1 hour.

[0075] In this embodiment, the smelting mixing furnace and the mixing box in steps S1, S2 and S3 are smelting and powder making devices.

[0076] Example 3

[0077] The difference between this embodiment and embodiment 1 is that the impurity of the metal component powder in steps S3 and S2 is 480 ppm and the particle size is 5 μm.

[0078] The warm pressing method in step S5 is to heat the powder and the mold to 133°C and perform warm pressing at a pressure of 1800 MPa and a temperature of 120°C.

[0079] The annealing heat treatment method in step S5 is to gradually increase the room temperature to an annealing temperature of 480°C, and the annealing time is 0.5h;

[0080] The equipment used in this embodiment is the same as that in the first embodiment;

[0081] Example 4

[0082] The difference between this embodiment and embodiment 1 is that the impurity of the metal component powder in steps S3 and S2 is 480 ppm and the particle size is 5 μm.

[0083] The warm pressing method in step S5 is to heat the powder and the mold to 133°C and perform warm pressing at a pressure of 1800 MPa and a temperature of 120°C.

[0084] The annealing heat treatment method in step S5 is to gradually increase the room temperature to an annealing temperature of 480°C, and the annealing time is 0.5h;

[0085] In this embodiment, the smelting mixing furnace and the mixing box in steps S1, S2 and S3 are existing vacuum smelting furnaces and ball mills.

[0086] Experimental example

[0087] 200 metal magnetic powder cores prepared in the above examples 1-4 were taken, and the same metal magnetic powder cores prepared by the existing metal magnetic powder core production process were taken. The prepared metal magnetic powder cores were tested for performance according to GB / T 13012-2008, HB20158-2014, GB / T 3658-2008, GB / T 20874-2007, IEC 60404-6 and IEC 60404-4. The test results are shown in the following table:

[0088]

[0089] In summary, the loss and magnetic permeability of the metal magnetic powder core produced by the metal magnetic powder core production process of the present invention are superior to those of the metal magnetic powder core produced by the metal magnetic powder core production process in the prior art.

[0090] Compared with the fourth embodiment, the third embodiment only differs in the processing equipment, and the equipment used in the processing steps is the same. The magnetic permeability, saturation magnetic flux density and working range temperature of the metal magnetic powder core in the third embodiment are significantly stronger than those in the fourth embodiment. Therefore, the use of the smelting and powder making device in the present invention can improve the magnetic permeability, saturation magnetic flux density and working range temperature of the metal magnetic powder core;

[0091] In Example 1, Example 2 and Example 3, only the processing conditions of S2 to S5 are different, and the equipment used in the processing steps is the same. The magnetic permeability and working range temperature of the metal magnetic powder core in Example 3 are significantly stronger than those in Example 1 and Example 2. It can be seen that different processing conditions will also affect the magnetic permeability and working range temperature of the metal magnetic powder core.

[0092] The specific embodiments described herein are merely examples of the spirit of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in similar ways, but they will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

Claims

1. A process for producing metal magnetic powder cores using waste materials, characterized in that: The following steps are involved: S1. Alloy smelting: silicon steel scrap or magnetic metal scrap is smelted at high temperature in a smelting mixing furnace, and efficient metal granulation is performed after smelting to facilitate subsequent powder processing; S2. Waste pulverization: The waste is granulated and effectively crushed, and the metal components are tested after being evenly mixed in a mixing box, and the required metal components are analyzed; S3, adding materials and making powder: adding the required metal components inside the mixing box, and performing synchronous and efficient mixing through the mixing box to ensure the powder making effect; S4, insulation coating: suspending metal powder particles in an organic solution of phosphoric acid and epoxy resin to form a solid fluid for insulation coating; S5. Pressing and annealing treatment: Use warm pressing to press the insulated coated metal magnetic powder into a green billet, and use annealing heat treatment to eliminate internal stress to ensure the magnetic properties of the metal magnetic powder core.

2. A process for producing metal magnetic powder cores using waste materials according to claim 1, characterized in that: The impurities of the metal component powder in steps S3 and S2 are less than 500 ppm, and the particle size is 3-5 μm.

3. The process for producing a metal magnetic powder core using waste materials according to claim 1, characterized in that: The warm pressing method in step S5 is to heat the powder and the mold to 120°C-135°C, and perform warm pressing at a pressure of 1100-1800 MPa and a temperature of 100°C-120°C.

4. The process for producing a metal magnetic powder core using waste materials according to claim 1, characterized in that: The annealing heat treatment method in step S5 is to gradually increase the temperature from room temperature to an annealing temperature of 480° C.-680° C., and the annealing time is 0.5 h-2 h.

5. A process for producing a metal magnetic powder core using waste materials according to any one of claims 1 to 4, characterized in that: The equipment used in steps S1-S3 is a smelting and powder making device; The smelting and powder making device comprises a smelting furnace (3), a mixing box (24), a fixed frame (1), and a cooling box (2) fixedly mounted on the surface of the fixed frame (1); the top of the cooling box (2) is fixedly connected to the smelting furnace (3), and a leakage hole (4) is provided at the bottom end of the smelting furnace (3), and a smelting and granulating component is connected to the bottom of the leakage hole (4); one side of the cooling box (2) is fixedly connected to a material guide trough (13), and the bottom end of the material guide trough (13) is fixedly connected to a crushing component, and the crushing component and the smelting and granulating component are transmission-connected; The smelting and granulating component comprises a rotating plate (5), and the rotating plate (5) is rotatably connected to the top of the cooling box (2), the outer wall of the rotating plate (5) is fixedly connected to a bevel gear ring (7), and the surface of the bevel gear ring (7) is meshingly connected to a bevel gear (8), the outer wall of the bevel gear (8) is fixedly connected to a rotating rod (9), and the rotating rod (9) is rotatably connected to the top of the cooling box (2), the rotating rod (9) is driven by a driving unit, and the rotating rod (9) is transmission-connected to a pulverizing component; The pulverizing assembly comprises a pulverizing box (15), and the pulverizing box (15) is fixedly mounted on the outer wall of the cooling box (2), the top of the pulverizing box (15) is fixedly connected to a top plate (14), and the top of the top plate (14) is fixedly connected to the bottom end of the material guide trough (13), the inside of the pulverizing box (15) is rotatably connected to two pulverizing rollers (17), and the outer walls of the pulverizing rollers (17) are meshingly connected to a material plate (16), and the material plate (16) is fixedly connected to the inner wall of the pulverizing box (15); The bottom end of the crushing box (15) is fixedly connected to a feeding pipe (23), and the bottom end of the feeding pipe (23) is fixedly connected to a mixing box (24); a circulation pipe (25) is spirally wound around the outer wall of the mixing box (24); a detection rod (27) is rotatably connected to the inside of the mixing box (24), and the detection rod (27) is transmission-connected to the crushing assembly; one end of the mixing box (24) is rotatably connected to a feeding assembly; One end of the circulation pipe (25) is fixedly connected to a connecting pipe (26), and the other end of the circulation pipe (25) is connected to the inner lower part of the cooling box (2) through a circulation water pump; A high-pressure nozzle (12) is fixedly mounted on the other end of the connecting pipe (26), and the high-pressure nozzle (12) is located inside and above the cooling box (2). An obliquely mounted screen (11) is provided below the high-pressure nozzle (12), and the screen (11) is fixedly mounted on the inner wall of the cooling box (2).

6. The process for producing a metal magnetic powder core using waste materials according to claim 5, characterized in that: The driving unit is a driving motor (10), and the output end of the driving motor (10) is fixedly connected to a rotating rod (9), and the driving motor (10) is fixedly installed on one side of the cooling box (2); A first sliding block (6) is fixedly connected to the outer wall of the rotating plate (5), and the first sliding block (6) is slidably connected to the interior of the cooling box (2).

7. The process for producing a metal magnetic powder core using waste materials according to claim 5, characterized in that: The feeding assembly comprises a rotating barrel (31), and the rotating barrel (31) is rotatably connected to one end of a mixing box (24), a plurality of material distribution chambers (32) are arranged in an annular shape inside the rotating barrel (31), and a feeding port (33) is provided on one side of each material distribution chamber (32), the feeding port (33) is in contact with the outer wall of the mixing box (24), and a material passage hole (38) is provided on the surface of the mixing box (24).

8. The process for producing a metal magnetic powder core using waste materials according to claim 7, characterized in that: The outer wall of the rotating barrel (31) is fixedly connected to an electric motor (35), and the output end of the electric motor (35) is fixedly connected to a gear plate (36), the bottom end of the gear plate (36) is meshingly connected to an outer gear ring (37), and the outer gear ring (37) is fixedly connected to the outer wall of the mixing box (24); The inner wall of the rotating barrel (31) is fixedly connected with a second sliding block (34), and the second sliding block (34) is slidably connected to the outer wall of the mixing box (24).

9. The process for producing a metal magnetic powder core using waste materials according to claim 5, characterized in that: Both ends of the two crushing rollers (17) are fixedly connected to a gear plate (18), and the gear plate (18) is located on the outer wall of the crushing box (15); one end of one of the crushing rollers (17) is fixedly connected to a connecting rod (19); the outer wall of the connecting rod (19) is fixedly connected to a first synchronous wheel (20); the outer wall of the first synchronous wheel (20) is meshed with a first synchronous belt (21); the top inner wall of the first synchronous belt (21) is meshed with a second synchronous wheel (22), and the second synchronous wheel (22) is fixedly mounted on the outer wall of the rotating rod (9).

10. The process for producing a metal magnetic powder core using waste materials according to claim 5, characterized in that: The outer wall of the detection rod (27) is fixedly connected with a third synchronous wheel (28), and the third synchronous wheel (28) is located at the outer end of the mixing box (24); the outer wall of the third synchronous wheel (28) is meshedly connected with a second synchronous belt (29), and the top inner wall of the second synchronous belt (29) is meshed with a fourth synchronous wheel (30), and the fourth synchronous wheel (30) is fixedly mounted on the outer wall of the connecting rod (19).

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